Guest Post: Total Cost of Ownership

john bowlerOur Guest Post today comes  from John Bowler, who is Visiting Professor at DeVry University’ s College of Business.

As the Heizer/Render OM text suggests in Chapter 11, the collaborative relationship between buyer and supplier should yield the lowest total cost of ownership (TCO). TCO is the sum of all direct, indirect, and opportunity costs over the life cycle of a purchase. The goal of the TCO approach is to obtain the most economical total price and not necessarily the lowest initial price. This is the focus of many successful collaborative supplier-client relationships.

The elements of TCO are (but not limited to): Item price; Item ordering cost; Transportation costs; Receiving costs; Inventory carrying cost; Shortage cost; Warranty cost; and Aftermarket/preventative maintenance cost.

TCO composition varies by the type of product, the product’s life-cycle stage, supplier’s location, the buyer’s production methodology and/or method of service delivery. Determining the TCO can be a challenging task. One way to start is to identify the supplier’s costs (or contributions) in regard to the following:

  • Integration relates to how well the supplier meshes with the buyer’s established infrastructure and processes to include the ease by which information flows both ways between buyer and the supplier. In today’s supply chain, timely and accessible information flow is very much as important as on time, in spec, delivery of the product or service.
  • Collaboration relates to the ease of doing business with the supplier.
  • Synchronization refers to supply chain capabilities such as the flexibility to drop ship direct to the end user.
  • Leverage focuses relates to the competitive advantage a supplier contributes to the client’s competitive capabilities.
  • Acceptable risk relates to the level of the supplier’s reliability and resiliency in supporting the buyer’s ability to maximize chosen profit opportunities.

TCO data-driven conclusions provide a competitive advantage to firms across various industries. Thinking outside the box of ways to maximize profitability in supplier relationships rather than calculating ways to minimize supplier costs will earmark industry leaders in the future.

OM in the News: How “Total Cost of Ownership” Brings Manufacturers Back to the US

Businessweek‘s (Feb.8,2012) headline reads: “For Some US Manufacturers, Time to Head Home”. It appears that when the total cost of ownership is computed (which  includes intellectual property risk, the cost/time to travel to visit distant suppliers, the negative impact of separating manufacturing from engineering back at HQ, and 28 more factors), the true costs of outsourcing can be assessed.

When measured on price alone, says the Reshoring Initiative, the cost of products and components made in the US vs. China are 108% higher. But when total cost of ownership is included, the US averages only 12% higher. “The US is a lot more competitive than people realize,” says the group’s founder. “Over the last several years, firms got caught up in the outsourcing trend without thinking through the costs.”

Two of the factors that drove firms overseas, cheap fuel and labor, no longer favor far-flung ventures. A barrel of oil has jumped from $23 to $88 in the past decade, so the price of shipping goods has gone up. And wages in China have increased 15% a year in that same time frame. Further, the dollar has declined 23% since 2002, with the result that factory labor here is 11% cheaper in dollar terms over that period.

As companies have also gotten better at reducing inventory and adopting JIT delivery, supply chains that stretch  around the world have started to look like liabilities. Researchers at Gartner predict that by 2014, 20% of the goods made in Asia that are destined for the US will shift to the Americas. And a recent survey by Accenture, called “Manufacturing’s Secret Shift,” reports that 61% of 287 manufacturers are thinking of moving operations closer to customers.

Don’t expect a hiring frenzy if some factories return, though. “It’s a marginal improvement, not a tidal wave,” says Businessweek.

Discussion questions:

1. Why won’t a shift in manufacturing result in millions of new jobs?

2. Why should the total cost of ownership be included in outsourcing decisions?